Characterization and Influences of the Load Carrying Capacity of Lightweight Hub Designs of 3D-Printed Gears (16MnCr5, PBF-LB/M-Process)

Lightweight design for gears is becoming increasingly important for efficient, sustainable drive trains. Innovative lightweight designs can be achieved by the additive manufacturing process of P.B.F.-L.B./M. (powder bed fusion by laser beam of metals). This contribution presents lightweight hub designs for gears manufactured by P.B.F.-L.B./M. Helical as well as spur gears are 3D-printed out of the case-hardening steel 16MnCr5. After the PBF-LB/M-process, the gears are case-carburized, shot blasted for mechanical cleaning. The gears with lightweight hubs are analyzed concerning their density, microstructure, roughness. The gears are tested regarding their static, dynamic load carrying capacity, the influence of the lightweight hub on the load carrying capacity is analyzed, evaluated. In conclusion, this contribution enables a profound understanding, prospective evolution of lightweight hub designs for gears.